certified Qualitysystem

ISO 9001 / EN 29001

Reg. Nr. 10529

A Honeywell Company

DKG 972

Gas Burner Safety Control

For 2-stage atmospheric gas burners
Flame detection:
- Ionisation probe
- Infrared-flicker detector IRD 1020
- UV flame sensor UVD 971
INTRODUCTION
The burner control box DKG 972 controls and supervises
atmospheric burners for gas. They are approved and certified
according to the applicable European standards and
regulations.
The microprocessor-based programming sequence ensures extremely stable timings independent of voltage variations, ambient temperature and/or switch-on cycles. The
built-in information system not only provides a continuous
monitoring of the actual state of the box (very helpful especially for monitoring the start-up phase) but also informs
about the cause of a possible lock out. The lock out cause
is stored in such a way that it can be retrieved even after a
power failure.
The control box is designed for maximum safety in case of
fluctuations in the voltage supply. If the mains voltage drops
below the permitted level, operation is interrupted and the
control box automatically prevents the start sequence from
being repeated. In this way, the safety of the system is not
put at risk by a drop in the mains voltage. This low-voltage
protection works not only during start-up but also permanently during operation.

TECHNICAL DATA
Operating voltage
Fuse rating
Power consumption
Max. load per output
- term. 3 ignition trafo
- term. 5 + 6 solenoid valves
- term. 7 alarm indicator
total load
Reset time from lock out
Sensitivity
min. ionisation current required
Sensitivity for stray light
Ionisation probe insulation
greater than 50 M
Stray capacitance
less then 1000 pF
max. cable length
Flame detectors
IRD 1020
UVD 971
Weight incl. Wiring base
Mounting position
Protection class
Approved ambient parameter
for control and flame detector
- for operation
- for storage
Build-up of ice, penetration of
water and condensing water are
Approvals according
to European standards

CONSTRUCTIONAL FEATURES
The control box circuitry is protected by a flame resistant,
transparent plug-in type plastic housing. A central fixing
screw locks the control box to the wiring base.
The plug-in control box incorporates the microprocessor
based timer, flame check and reset circuits.
Manual reset from lock out and set to lock out is provided by
a push button with an integrated LED information system.
A variety of cable entry points provides complete flexibility
for electrical wiring.
The wiring base S98 is equipped with spare- and extraterminals
and allows together with a variety of cable entry points utmost
flexibility of electrical wiring.
The DKG 972 are compatible with the TFI 812.
Different are only the pre- and post-ignition times.

0651.10-00-e/01/99

Max. heating power according the limits in the Gas Appliance

Directive.

Classified acc. to EN 298

220 / 240 V (-15... +10%)

50 Hz (5%)
10 A fast, 6 A slow
ca. 15 VA
1.0 A, cos 0.2
0.5 A, cos 0.4
0.5 A, cos 0.4
4.0 A, cos 0.4
max. 6 A during 0,5 sec
none
1 A
1.5 A
0.4 A
probe - earth
probe- earth
<3m
side-on or end-on viewing
end-on viewing
190 g
any
IP 40
max. 95% at 30 C
-20 C... +60 C
-20 C... +80 C
inadmissible
EN 298 and EN 230, as
well as all other relevant
Directives and standards
FTLLXN

Timings (sec.)
Model
05
10
20

waiting time start

tw
12
12
12

pre-ignition time
tvz
3
3
3

Stray light monitoring

tf
5
5
5
1

safety time
ts
5
10
20

post-ignitiontime
tn
4.5
9.5
19.5

delay 2nd-stage
tv2
25
25
25

APPLICATION FEATURES

1.2 Lock-out diagnoses

In case of a failure the LED is permanently illuminated. Every
10 seconds the illumination is interrupted by a flash code,
which indicates the cause of the error. Therefore the following
sequence is performed which is repeated as long as the unit
is not reset.

1. Information system
The information system is microprocessor based and reports on all aspects of burner control box operation and
flame supervision. It informs continuously about the actual
programming sequence the unit is just performing. Besides
monitoring of the programming sequence it also allows to
identify errors during start-up of operation without any
additional testing devices. The automatically performed
diagnosis is a valuable tool which facilitates service/
maintenance work and therefore saves costs. The analyses
of the error cause can be done directly on stage or if not
possible afterwards as the lock out reason is stored in a nonvolatile lock out mode memory.
The information system communicates with the outside
world using a LED (the used Flash-Code is similar to the
Morse-Code). The messages are optically transmitted by a
appropriately flashing LED. Using an additional terminal
(optional), the messages can be recorded and displayed in
easy readable form.

Sequence:
dark phase

for 10 sec

for 0.6 sec

Error diagnosis
Error message
lockout

Flash-Code

stray light

Flash-Code dark phase

for 1.2 sec

Possible fault
within lock out safety time
no flame establishment
stray light
during monitored phase,
detector may be faulty

Flash-Code for manual lock out

manual/external
_
lock out
(see also 3. lock out and reset)

1.1 Programming sequence display

The built-in microprocessor controls not only the programming sequence but the information system too. The
individual phases of the programming sequence are
displayed as Flash-Code.
The following messages can be distinguished:
Message
waiting time
tw
pre-ignition
tvz
safety time ts
post ignition tn
delay time to valve V2
tv2
running
low mains voltage

illuminated phase

2. Flame detection
The following types of flame detectors are suitable:

Flash-Code
.

Ionisation probe, temperature resistant material, well

insulated (material and insulation same as for ignition
electrode).
Infrared-flicker detector type IRD 1020 with mounting
flange M 93 or the UV solid state flame sensor UVD 971.
Flame detection using an ionisation probe is only possible
in conjunction with mains supplies which provides a neutral earth connection.
Connecting the IRD 1020 or UVD 971 the correct wiring
has to be observed.

.
.
.
_
_

Description
x = short pulse
z = long pulse
. = short pause
_ = long pause

2.1 Stray light monitoring

DKG 972

The stray light check is performed at the end of the prepurge time for thr duration as mentioned in the technical
datas.

3. Lock out and reset

6. Mounting and electrical wiring

The unit can be reset or brought into lock out mode in two
different ways:

Wiring base:
3 earth terminals with additional terminal for burner
earthing
3 neutral terminals with internal permanent connection to
neutral terminal 8
2 independant spare terminals (S1 and S2)
extra terminals A, B and C are standard
2 slide-in plates and 2 easy knock out holes (PG11
thread) plus 2 knock out holes in the base bottom faciliate
the base wiring

Internal
In the lock out case the unit can be reset by pushing the builtin button meaning a new start-up cycle is performed.
External
Instead of using the built-in lock out button the same
function can be achieved by using an external button which
connects terminal 9 with A (see also circuit and block
diagram).

The digital controls are ideally wiried on the new wiring

bases S98, which are equipped with (terminals B and C are
only for some special types of DMO or DMG) terminal A,.
which is used for the remote reset / remote lockout functions.

If the pushputton (internal or external) is pressed during

normal operation or during the start sequence for more then
3 sec. and afterwards released, the control box will perform
a shutdown.

Please note
To assist trouble-free operation the main neutral
connection terminal in the wiring base must be
fully tightened. The terminal screws are already
in the undone position. To connect a wire to the
terminal, the screw only needs to be fastened.

Please note
The unit can only be brought to lockout mode or
be reseted if power is applied to the unit.

General: The control box and detector probes should not be

subjected to excessive vibration.

4. Low-voltage protection
The mains voltage has to be more than 187 Veff in order to
allow the unit to perform a start-up.
The mains voltage is not only monitored in the start-up
phase but also permanently during operation. If the voltage
drops below < 160 Veff during start-up or run time the control
box goes into lock out mode. If the voltage rises again, the
control box performs automatically a start-up as soon as the
mains voltage is > 187 Veff.
5. Safety

DKG 972

The design and control sequence of the DKG 972 controls

will comply with the currently applicable standards and
regulations (see also TECHNICAL DATA).

INSTALLATION INSTRUCTIONS AND MAINTENANCE

3. Fault finding
The built-in information system facilitate the trouble shooting
in the case of problems occurring during start-up or during
operation.
A list of possible lock out messages can be found in
APPLICATION FEATURES chapter 1.2.

1. Important notes
The controls must be installed by qualified personnel
only. The relevant national regulations have to be
observed.
On commissioning the wiring has to be carefully checked according the appropriate diagram, Incorrect wiring
can damage the unit and endanger the installation.
The fuse rating has to ensure that the limits specified in
TECHNICAL DATA will not be exceeded. If these precautions are not observed, the effect of a short circuit can
cause severe damage to the control and installation.
For safety reasons a minimum of one control shutdown
every 24 hours has to be observed.
Disconnect the mains before the control box is plugged
in or out.
The control box is a safety device and must not be
opened!

Please note:
The control box is locked in lock out mode
and the reasen for the lock out is displayed
until the control box is reset, either by an
internal or external reset (see also subject 3.
Lock out and reset").
Removing the control box from its wiring base or by
interrupting the supply line may not reset a lock out. Therefore,
by applying power, it needs 2-3 secs. before the control box
goes to lock out again and the cause of the last lock out.
Error
Burner not working

Possible fault
- Thermostat circuit open
- Faulty electrical wiring
- mains voltage < 187 V
After 2-3 secs. after applying - Control box has not been reseted
power. the unit goes to
lock out
Burner starts,
- No ignition or no fuel
flame not established,
lock out
Burner starts,
- no or too low flame signal (min.
flame established,
valves see TECHNICAL DATA)
after safety time,
- wrongly wired, phase and neutral
lock out
reversed
- Ionisation probe dirty, broken or
has contact to frame ground
- too little light on flame sensIor
(IRD)

2. Function control
For safety reasons the flame detection system should be
tested on commissioning the installation as well as after a
service or longer shut-down.
a) Attempt to start with gas valve closed:
At the end of the safety interval
-> Lockout

DKG 972

b) After a normal start, with the burner in operation, close

the gas valve:
At the end of the safety interval, system attempts to
restart
-> Lockout

CIRCUIT AND TIMING DIAGRAM DKG 972

Ph

max. 10 A fast
6 A slow
1

HS

ST

GW

RT

EV

A
HS
GW
ST
RT
EV
IS

V1
IS
V2

SA

tw tvz tn ts

tv2

IRD- OR UVD CONNECTION

term. 8
term. 1
term. 9

blue
black
brown

IRD 1020
UVD 971

BLOCK DIAGRAM DKG 972

Oscillator

EEPROM

Fault display
Information
system

C
Watchdog

Reset and
lock out

Reset

Mains
monitoring

Power
supply
monitoring

Flame
amplifier

RZ

RV1

rz

rv1

RV2

RS

Power
supply

rs

rv2
3

DKG 972

Z
V1
V2
SA

Mains switch
Gas proving switch
Limit thermostat
Control thermostat
External reset and lock out button
Ionisation probe
(IRD 1020, UVD 971see separate diagram)
Ignition
Solenoid valve, 1st-stage
Solenoid valve, 2nd-stage
External lock out signal

tw
tvz
tn
ts
tv2

Waiting time
Pre-ignition time
Post-ignition
Safety time
2nd-stage delay

24

62,5

38,5

4,5

DKG 972 AND SOCKET

PG 11

86

60

Slide-in plate
24

35

Earth

25

30
16

30
44

Reset button

M4

Underside cable
entry 16 mm

30
57-60

UVD 971

HOLDER M 93 FOR IRD

IRD 1020

29

50

29

UVD = 29
IRD = 44

35

13,5

14

UVD = 89
IRD = 104

4.5
26

21,8

21,8

15.1

VARIATION IRD
right

17

48

axial
left

20.5

ORDERING INFORMATION
ITEM
Control box
Control box
Control box
Socket
Insert plate
optional
Flame detector
Flame detector
Flame detector
optional
Support for IRD
Support for UVD
Connection cable

DESIGNATION
DKG 972 Mod. 5
DKG 972 Mod. 10
DKG 972 Mod. 20
Wiring base S98
PG-Plate
Cable entry plate
IRD 1020 end-on
IRD 1020 left
IRD 1020 right
UVD 971
Holder M93 for IRD 1020
Holder M74 for UVD
Plug type, 3 core cable, 0.6 m with tag wire ends

The above ordering information refers to the standard version.

Special versions are also included in our product range.

DKG 972

Specifications subject to change without notice

A Honeywell Company

ITEM NO.
0332005
0332010
0332020
75310
70502
70501
16522
16523
16521
16722
59093
59074
7236001

Satronic AG
Brelstrasse 7
Postfach 324
CH-8157 Dielsdorf